Target Audience:
Harley-Davidson Sportster XL1200 Sport owners, independent repair shops, and DIY enthusiasts seeking detailed technical guidance.
Manual Advantage:
Provides factory-level detail essential for maintaining and repairing the specific nuances of the XL1200 Sport model, superior to generic aftermarket guides.
Key Manual Features:
Factory diagrams, torque specifications, wiring schematics, step-by-step procedures, and troubleshooting guides.
Sport Model Features:
The 'Sport' designation often indicates higher-spec suspension (e.g., adjustable Showa forks, dual adjustable shocks) and potentially performance-tuned engine components, all detailed in this manual.
Engine System:
Complete disassembly, assembly, inspection, troubleshooting, and repair of the Evolution 1200cc V-twin engine, including top-end, bottom-end, lubrication, ignition, and fuel systems.
Transmission System:
Service and repair of the 5-speed constant mesh transmission, clutch operation, and primary drive system.
Chassis Frame Suspension:
Inspection and repair of the frame, front fork (including Showa cartridge forks common on XL1200S), rear shock absorbers, swingarm, and wheel bearings.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, hydraulic lines, and rotor inspection/replacement.
Electrical System:
Wiring diagrams, component testing, battery, charging system (stator, regulator/rectifier), starting system, lighting, instrumentation, and accessory circuits.
Fuel System:
Carburetor (e.g., Keihin CV) disassembly, cleaning, adjustment, fuel tank, fuel lines, and petcock service.
Exhaust System:
Exhaust pipe and muffler inspection, replacement, and torque specifications.
Bodywork Trim:
Fender, tank, seat, handlebars, and controls removal and installation procedures.
Instrumentation Controls:
Calibration and troubleshooting of speedometer, tachometer, and warning lights.
Routine Maintenance:
Oil change, filter replacement, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable for earlier models/variant), brake fluid flush, battery maintenance.
Troubleshooting:
Diagnostic charts and procedures for common engine, electrical, and mechanical issues.
Engine Repair:
Piston and ring replacement, valve adjustment, camshaft inspection, crankshaft and connecting rod service.
Transmission Repair:
Gear inspection, shift drum and fork alignment, clutch plate replacement, and primary chain tensioner adjustment.
Electrical Diagnostics:
Testing of ignition coil, starter solenoid, lighting circuits, and instrument panel functionality.
Suspension Adjustment:
Fork oil level and viscosity checks, rear shock pre-load adjustment.
Wheel Tire Service:
Tire pressure checks, wheel balancing, and spoke tension (if applicable).
Component Replacement:
Detailed instructions for replacing components such as alternators, starters, brake pads, and fuel pumps.
Depth Of Information:
Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis component overhauls.
Diagnostic Charts:
Includes detailed diagnostic flowcharts and symptom-based troubleshooting guides.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.7 cubic inches)
Bore X Stroke:
3.500 in x 3.812 in (88.9 mm x 96.8 mm)
Compression Ratio:
Approximately 9.0:1 (check specific model year for exact figures)
Valve Train:
Overhead valves (OHV), pushrod actuated, two valves per cylinder.
Horsepower Estimated:
60-70 HP (at crankshaft, typical for this era)
Torque Estimated:
65-75 ft-lbs (at crankshaft, typical for this era)
Fuel Delivery:
Carburetor (typically Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended.
Ignition Type:
Electronic Ignition (CDI)
Oil Type:
Harley-Davidson 20W-50 Motorcycle Oil or equivalent JASO MA certified oil.
Oil Capacity:
Approximately 3 quarts (2.8 liters) with filter change.
Engine Oil Filter Change:
Every 2,500 - 5,000 miles or annually, whichever comes first (refer to manual for exact interval).
Spark Plug Replacement:
Every 5,000 - 10,000 miles (check plug condition at each service).
Air Filter Cleaning Replacement:
Inspect every 2,500 miles, clean/replace as needed based on riding conditions.
Brake Fluid Flush:
Every 12-24 months, or as recommended by fluid manufacturer.
Primary Chain Case Fluid:
Harley-Davidson primary lubricant or equivalent (check manual for specific type and capacity).
Transmission Fluid:
Harley-Davidson transmission lubricant or equivalent (check manual for specific type and capacity).
Fork Oil:
Specific weight and viscosity fork oil, typically HD Formula+ or equivalent (refer to manual for exact type and fill level).
Carburetor Tuning:
CV carburetor can require periodic adjustment for optimal performance, especially with aftermarket exhaust or intake modifications.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent faults.
Primary Chain Tensioner:
Hydraulic tensioner can wear over time, potentially leading to noise or chain slack.
Rear Shocks:
Original rear shocks may lose damping effectiveness over time, especially on higher-mileage bikes.
